System and method for automated successive three-dimensional printing

ABSTRACT

A system and method for autonomously creating subsequent physical objects using a 3-dimensional printer. The system includes a build platform that melts or sublimates at a lower temperature and pressure than the glass-transition temperature of the printed object, allowing the printed object to become detached and removed from the build area with minimal force.

CLAIM OF PRIORITY

This application is a continuation of U.S. patent application Ser. No.17/248,786, filed Feb. 8, 2021, which is a continuation-in-part of U.S.patent application Ser. No. 16/946,188, filed on Jun. 9, 2020, now U.S.Pat. No. 11,110,658, issued Sep. 7, 2021, which is a divisional of U.S.patent application Ser. No. 15/801,016, filed Nov. 1, 2017, now U.S.Pat. No. 10,723,075, issued Jul. 28, 2020 which claims priority to U.S.Provisional Patent Application No. 62/416,428, filed Nov. 2, 2016, whichare incorporated by reference in their entireties.

NOTICE OF COPYRIGHTS AND TRADE DRESS

A portion of the disclosure of this patent document contains materialwhich is subject to copyright or trade dress protection. This patentdocument may show and/or describe matter that is or may become tradedress of the owner. The copyright and trade dress owner has no objectionto the facsimile reproduction by anyone of the patent disclosure, as itappears in the Patent and Trademark Office patent files or records, butotherwise reserves all copyright and trade dress rights whatsoever.

FIELD OF THE EMBODIMENTS

The present disclosure relates generally to a system and method forautomated successive three-dimensional printing. More particularly, thepresent disclosure relates to a system and method for automatedsuccessive three-dimensional printing which can operate without a humanbeing present.

BACKGROUND

Additive manufacturing (also known as “3D printing”) is performed by aspecial-purpose device which operates by depositing thin layers ofthermoplastic or other reformable or reactive material onto a flatplanar surface. This is done by depositing said material between precisepoints until the sum of all layers forms the ultimate shape of a desiredobject. One requirement that this type of system has is that the firstlayer of material deposited on the build surface must adhere to thatsurface. This adhesion is important because it ensures that the forcesof the subsequent material being deposited does not change the positionof the first layer relative to all subsequent layers. While a lateralshift of any layer results in inaccurate printing, a shift in the firstlayer typically results in catastrophic failure of the print job.

This adhesion requirement introduces a certain “Goldilocks” paradigm: aprint surface must provide sufficient adhesion such that the risk offirst layer detachment over the course of a print job is sufficientlylow, yet not so much adhesion that the desired object is now permanentlyfused to the build platform. Put simply, a build platform that providestoo much adhesion requires significant physical force to remove theobject, while a build platform with too little adhesion causes theprinter to be unreliable or inaccurate.

Already existing in the art are a number of solutions to address thisadhesion requirement, however each solution has significant limitationsor drawbacks. Such solutions include painter's tape, ultra-hold hairspray, and polyimide tape. Each of these materials are produced by avariety of companies, each with their own specific chemicalformulations. However, a common drawback of all these materials is thatthey lack staying power. That is, they all wear out or become damagedduring the removal of the print, possibly after only a single use.

Another solution to the adhesion requirement of 3D printing is to havethe build platform be inherently adhesive. To address ejecting theprinted objects, some of these build platforms are constructed out of aflexible base material, which allows the end user to apply a bendingforce to the build platform to unstick the printed object from the buildplatform.

Regardless of the composition of the build platform, most 3D printersthat exist today merely leave the completed object on the buildplatform, waiting for the user to manually remove the object so that thenext print job can initialize. This creates a bottleneck in theproduction of 3D-printed objects, preventing 3D printing from being usedas a manufacturing tool. Because of this, 3D printers cannotautomatically process their print queues, and cannot be operated withany kind of autonomy. For 3D printers to fulfill the vision asdeliverers of digital ideas into our physical world, a mechanism forremoving a print job from the build platform is necessary.

One solution to this automated ejection problem is the “Automated BuildPlatform” product offered as an aftermarket add-on kit by MakerBotIndustries, disclosed in U.S. Pat. Nos. 8,282,380 and 8,287,794. There,the build platform surface is constructed out of a thin, flexiblesubstance concatenated with itself to form a closed-loop, movableconveyor belt, supported by an underlying flat hard surface. Onceprinting is completed, the conveyor belt advances using the rotationalforce of motorized frictional cylinders on one end, and the objectdetaches from the flexible surface at the rotating point, also pushingit from the completed build platform. The movement of the build surfaceas a conveyor belt both provides the detaching force at the rotationpoint as well as the linear movement of the object out of the buildspace. However, when implemented in real-world printers, warping of theobject proved to be an insurmountable problem as a print bed that ejectswarped objects is not functional. That is, the upward curling force ofuneven thermoplastic cooling was too great for the thin surface materialto counteract, and objects with large surface areas were either toowarped to be acceptable, warped to the point of causing catastrophicprint failure, or in the event of a small object not being large enoughto warp, too well-adhered to be removed by the rotating force of thesurface. Attempts were made to correct this by constructing the buildplatform out of thin metal, like titanium. Notwithstanding thedramatically increased cost of a titanium build platform, large objectsstill produced the devastating warping effects that the thin metalcouldn't counteract.

Another solution that exists today is taught in U.S. Pat. No. 9,289,946.That solution leverages the mechanical advantage of a wedge and uses ablade to apply a separating force to break the bonds between the bottomsurface of the printed object and the printing surface. Further, theblade's motion-path back to its starting position doubles as the forceto push the now-separated object out from the build volume.Alternatively, this blade/wedge-separation method may employ asecondary, separate device to remove the object from the print areaafter separation to similar effectiveness at the cost of increasedexpenses and mechanical complexity, should there be an engineeringreason to do so. However, this solution is mechanically complex and haslimits on the size of objects that can be ejected because as an object'sbottom surface area increases, the force of adhesion between the objectand the build platform increases as well. Therefore, the force needed todrive a blade underneath the first layer of the build object increasesdrastically with the footprint of the build object. Additionally, theblade may dull over time, requiring sharpening or replacement, adding toa printer's maintenance overhead. The blade also requires exactcalibration, as the blade must run along the surface of the buildplatform, but not cause damage or excessive wear to it. Finally, thismechanism requires additional space alongside an arbitrary axis of thebuild surface area, decreasing the printer-size-to-build-volume ratio ofthe 3D printer.

The most prolific automated solution to ejecting printed objects fromthe build platform is the automated application of a large brute forceon the completed object. This force is sufficient such that the bottomlayer of the printed object detaches from the build platform and theobject's momentum moves it out from the printer's build volume, freeingthe printer to initialize a subsequent print. This is achieved via adedicated ramming device or via the print head itself. The success ofthis method is firstly dependent on the condition that the force on theobject is sufficient such that separation occurs between the object andthe build platform, as there is no mechanical advantage to this method.In the case of using the print head to ram the object off the buildplatform, the components that support the print head must be able towithstand this force. Typically, the supports are precision-machinedguide rods, which, for small objects, are sufficient. However, for largeobjects with a high degree of adhesion to the build surface, the forceof impact may be sufficient to permanently deform the rods that allowthe motion of the print head, effectively breaking the printer untilthey are replaced. This method also requires that the adhesion betweenlayers of the object is higher than the adhesion between the object andthe build surface, otherwise the object would shear at an arbitraryz-height, which could cause either errors or breakage of the printerwhen attempting to print the next object. With this method beingeffective only for printed objects that are strong in their inherentshape and small in their surface area contact with the print platform,this method leaves much to be desired.

Another solution is taught by International Patent Application No.: WO2015/116639. This invention consists of two critical components: aflexible, flat planar build surface; and a two-part mechanical system todeform this surface along one axis and then also to vacate the now-freedcompleted object from the build surface. The combination of deformableplanar surface and mechanical system serve to replace the need for humanlabor to clear a printer's build surface for a subsequent print tocommence. This method is dependent on the aforementioned “goldilocks”build platforms which are constructed out of a flexible metal surfacecoated with a substance that increases desirable adhesion propertiesbetween printed plastic and the build platform, or a flexible non-metalmaterial that inherently has desirable adhesion properties. Between thecoated-metal vs. proprietary inherent material flexible products,flatness of the build surface is difficult to achieve or is highlyexpensive. Additionally, the natural fatigue of both metal and polymerflexible build products must be considered. After certain flex/flattencycles, the material may either begin to crack or degrade from thestress, or possibly no longer be able to return to a fully flattenedstate—a hard-stop for accurate 3D printing, again leaving much room forimprovement.

As can be seen based on the above solution, the current state of the artonly provides very compromised options, either limiting the type ofobject that can be printed or adding significant mechanical complexityand chemical-manufacturing dependencies to the 3D printer itself.

While these units may be suitable for the particular purpose employed,or for general use, they would not be as suitable for the purposes ofthe present disclosure as disclosed hereafter.

In the present disclosure, where a document, act, or item of knowledgeis referred to or discussed, this reference or discussion is not anadmission that the document, act, item of knowledge, or any combinationthereof that was known at the priority date, publicly available, knownto the public, part of common general knowledge or otherwise constitutesprior art under the applicable statutory provisions; or is known to berelevant to an attempt to solve any problem with which the presentdisclosure is concerned.

While certain aspects of conventional technologies have been discussedto facilitate the present disclosure, no technical aspects aredisclaimed. It is contemplated that the claims may encompass one or moreof the conventional technical aspects discussed herein.

SUMMARY

The present disclosure teaches a print area, for accepting andsubsequently ejecting an object printed thereon by a 3-dimensionalprinter, the print area comprising: a build plane; a build platformconstructed entirely out of a molecular solid capable of beingsublimated at substantially 1 atm, having a top surface, a bottomsurface, and a reservoir configured to contain the build platform; apush mechanism, having a horizontal actuator attached to a plow, wherethe plow is located proximately to the build platform, wherein theactuator is configured to provide sufficient force to eject the objectbeyond the holding bracket; and a temperature regulator, located belowthe bottom surface. Preferably, the build platform is constructed out ofa material with a melting point between 25° C. and 60° C., which ispreferably gallium. Also preferably, the temperature regulator is aPeltier device. In some embodiments, the print area also has a trayhoused within the reservoir attached to a lift mechanism having avertical actuator having a top end connected to the tray. Preferably,the tray is hingably attached to the top end of the actuator. In otherembodiments, during the step of cooling by the temperature regulator,the temperature changes such that the build surface deposits within thereservoir. Preferably, the molecular solid is octacyclic sulfur,naphthalene, hexachlorobenzene, (+)-camphor, dimethyl sulfone,(−)-menthol, or (S)-ibuprofen.

The present disclosure also teaches a method of ejecting an object froma print area, the object being printed by a 3-dimensional printer, theprint area comprising a build plane, a build platform, having a topsurface, a bottom surface, and a reservoir that extends therebetween andsurrounds the build platform, a push mechanism, having a horizontalactuator attached to a plow, where the plow is located proximately tothe build platform, wherein the horizontal actuator is configured toprovide sufficient force to eject the object beyond the build platform,and a temperature regulator, located below the bottom surface, whereinan air-tight chamber envelopes the build platform, the push mechanism,and the temperature regulator, the method comprising the steps of:providing, by the 3-dimensional printer, a printed object, wherein theprinted object is adhered to the top surface of the build platform;heating the build platform, by the temperature regulator, to asublimation point of the build platform; allowing, the build platform tosublimate and the object to become disjoined from the top surface of thebuild platform; pushing object off the build platform by the plow of thepush mechanism. In other embodiments, the print area has an air-tightchamber enveloping the build platform and the push mechanism, andoptionally also envelops the temperature regulator. Preferably, thebuild platform is constructed out of iodine in this configuration. In analternative embodiment, there is a pressure modulator configured toregulate the pressure within the air-tight chamber. In anotherembodiment of the method in accordance with the present disclosure, thestep of heating the build platform is followed by the step of changingthe pressure in the air-tight chamber by a pressure modulator. In afurther embodiment, during the step of cooling, the temperatureregulator and pressure modulator change the temperature and pressuresuch that the build surface deposits within the reservoir.

This invention addresses the need for an automated method of creatingsubsequent physical objects using additive manufacturing, a processcolloquially known as “3D printing.” By using a variety ofelectrochemical and/or electromechanical enhancements to the traditionalstatic print bed, a 3D printer deploying the disclosed methods couldprocess its print queue without human intervention. The methods pursuedherein aim to circumvent limitations present in attempts outlined in theprior art by being feasible with both delicate printed parts that cannotwithstand large moments of force against them, or large objects with aconsiderable surface area interface between the printed part and thebuild platform.

The claims should not necessarily be construed as limited to addressingany of the particular problems or deficiencies discussed hereinabove. Tothe accomplishment of the above, this disclosure may be embodied in theform illustrated in the accompanying drawings. Attention is called tothe fact, however, that the drawings are illustrative only. Variationsare contemplated as being part of the disclosure.

Implementations may include one or a combination of any two or more ofthe aforementioned features.

These and other aspects, features, implementations, and advantages canbe expressed as methods, apparatuses, systems, components, programproducts, business methods, and means or steps for performing functions,or some combination thereof.

Other features, aspects, implementations, and advantages will becomeapparent from the descriptions, the drawings, and the claims.

BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the drawings, like elements are depicted by like reference numerals.The drawings are briefly described as follows.

FIG. 1A is a side view, showing another example embodiment of the buildplatform according to the present disclosure, with a print objectdisposed thereon.

FIG. 1B is a side view, showing the build platform of FIG. 1A, whereinthe top surface of the build platform has been melted.

FIG. 1C is a side view, showing the build platform of FIG. 1B, with theprint object being ejected from the melted top surface via a pushmechanism.

FIG. 1D is a side view, showing the build platform of FIG. 1B, with theprint object being ejected from the melted top surface via a liftmechanism.

FIG. 1E is a side view, showing an example embodiment of the buildplatform according to the present disclosure, with the print objectbeing ejected from the melted top surface via a push mechanism.

FIG. 1F is a side view, showing an example embodiment of the buildplatform where the print object is supported by a support mechanismwhich is capable of melting.

FIG. 2A is a side view, showing another example embodiment of the buildplatform according to the present disclosure, with a print objectdisposed thereon.

FIG. 2B is a side view, showing the build platform of FIG. 2A, whereinthe top surface of the build platform has been sublimated.

FIG. 2C is a side view, showing the build platform of FIG. 2B, with theprint object being ejected from the sublimated top surface via a pushmechanism.

FIG. 2D is a side view, showing an example embodiment of the buildplatform, where the print object is supported by a support mechanismwhich is capable of sublimating.

The present disclosure now will be described more fully hereinafter withreference to the accompanying drawings, which show various exampleembodiments. However, the present disclosure may be embodied in manydifferent forms and should not be construed as limited to the exampleembodiments set forth herein. Rather, these example embodiments areprovided so that the present disclosure is thorough, complete, and fullyconveys the scope of the present disclosure to those skilled in the art.In fact, it will be apparent to those skilled in the art that variousmodifications and variations can be made in the present inventionwithout departing from the scope or spirit of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments of the present invention will now be describedwith reference to the drawings. Identical elements in the variousfigures are identified with the same reference numerals.

Reference will now be made in detail to each embodiment of the presentinvention. Such embodiments are provided by way of explanation of thepresent invention, which is not intended to be limited thereto. In fact,those of ordinary skill in the art may appreciate upon reading thepresent specification and viewing the present drawings that variousmodifications and variations can be made thereto.

Exhibited below are several solutions for solving the problem ofprinting subsequent objects using additive manufacturing hardwarewithout human intervention between each such print jobs.

FIGS. 1A-1F show an alternative embodiment of the print area accordingto the present disclosure. As shown in FIG. 1A, the print area includesthe build platform 100, a temperature controller 500 located beneath thebuild platform 100, and the build plane 400 which is level with thebuild platform 100. This embodiment of the build platform 100 includes atop surface 100A, a bottom surface 100B, and a reservoir 100D thatextends between the top surface 100A and the bottom surface 100B andsurrounds the build platform 100. Of note here is the composition of thebuild platform 100. In the embodiments shown in FIGS. 1A-1F, the buildplatform 100 is constructed out of a metal, alloy, or other substancethat can readily and reversibly change phase, and that has a meltingtemperature lower than that of the material that the object 1000 isconstructed out of. This substance should have a melting temperature inthe range of 25° C. to 65° C. A more preferred range is between 35° C.and 55° C., and a highly preferred range is between 40° C. and 55° C.This melting of the build platform 100, in relation to the object 1000,is shown in FIG. 1B.

While the object 1000 is being printed on the build platform 100, thebuild platform 100 is solid. Upon completion of the 3D printing process,the build platform 100 is heated by the temperature controller 500. Thetemperature controller 500 can be either an electric resistive heater,or a Peltier device. However, a Peltier device is beneficial as itprovides the added functionality of being able to cool whatever it isattached to as well, allowing for materials with a melting point closerto room temperature to be used in the build platform 100. This isbeneficial as it can more readily prepare the build platform 100 forsubsequent printing and has the ability to lower the temperature of thebuild platform 100 in the event that it becomes critically high.However, resistive heaters are far smaller and less expensive, so thereexist other embodiments which employ a resistive heater to cause thephase change in the build platform 100. In some embodiments, only thetop surface 100A of the build platform 100 is constructed out of thisphase-changing material, as shown in FIG. 1E.

Regardless of interim conditions of the print area, upon the melting ofthe build platform 100, there is no force keeping the completed object1000 stationary on the build platform 100. As such, the object 1000 canbe removed from the print area without the use of significant effort.Various mechanisms can be used to eject the completed object 1000 fromthe build platform 100 upon the melting of the build platform 100. Onemechanism is the push mechanism 200, shown in FIG. 1C. Here, the pushmechanism 200 includes a plow 201 attached to a horizontal actuator 202.Upon the melting of the build platform 100, the push mechanism 200 willuse the plow 201 to eject the object 1000 beyond the build platform 100.

In some embodiments, it may be advantageous to have the reservoir 100Dextend above the build plane 400 such that melted build platform 100doesn't spill beyond the reservoir 100D. As most materials are lessdense in their liquid form, this is an important consideration. However,if the reservoir 100D extends above the build plane 400, the use of thepush mechanism 200 could potentially damage the object 1000.Accordingly, an alternative ejection mechanism is contemplated by thepresent disclosure. As shown in FIG. 1D, the print area also includes alift mechanism 600 having a vertical actuator 601 and a tray 602.Preferably, the tray 602 will be hingably attached to the verticalactuator 601.

Also of note for the embodiments shown by FIGS. 1A-1F, when used inconjunction with 3D printers using fused deposition modeling (“FDM”),fused filament fabrication (“FFF”), or extrusion-added construction(“EAC”) technologies, it is ideal that the melting temperature of thebuild platform 100 is not only lower than the melting temperature of theobject 1000, but also that the melting temperature is lower than theglass-transition temperature of the material being printed. If thistemperature is higher than the glass-transition temperature of theobject 1000, melting the build platform 100 could possibly lead towarping, deformation, or collapse of the object 1000. However, it isalso important to note that if the melting temperature of the buildplatform 100 is too low, then the heat absorbed while printing the firstfew layers of the object 1000 could cause premature melting or softeningof the build platform material. For this reason, gallium or its alloysis an example of a highly preferred material for the build platform 100,as pure gallium melts at 29.77 degrees Celsius. Ideally, a gallium-alloywhich has a melting temperature in the 40° C. to 55° C. range is used.This is below one of the lowest glass-transition temperatures of common3D printing thermoplastics, that of PLA which is 60-65 degrees Celsius,making it very suitable for this application.

In FIG. 1F, an alternative embodiment of the print area is shown. Here,the build platform 100 is similar to the other embodiments shown inFIGS. 1A-1E, however, the 3D printer deposits additional phase-changingmaterial on top of the build platform 100. That is, the 3D printerprints a custom support structure 1200 to support the object 1000against gravity as required, whereby the object 1000 can be easilydeposited thereon. After the object 1000 has been successfully printed,the support structure 1200 will change phase and will no longer beadhered to the object 1000. The support structure 1200 can be depositedby the same head that prints the object 1000 or may be deposited by aseparate print head. Here, the phase change is melting and the supportstructure 1200 could be printed at a particular temperature, preferablyat the melting point of the material the support structure 1200 isconstructed out of, such that the support structure 1200 would coolbelow the melting temperature and solidify in the custom desired shape.

Referring to FIGS. 2A-2D, yet another embodiment of the print areaaccording to the present disclosure is provided. As shown in FIG. 2A,the print area includes the build platform 100, the temperaturecontroller 500 located beneath the build platform 100, the build plane400 which is level with the build platform 100, an air-tight chamber700, and a pressure modulator 800. This embodiment of the build platform100 includes a top surface 100A, a bottom surface 100B, and a reservoir100D that extends between the top surface 100A and the bottom surface100B, and also surrounds the build platform 100. The embodiments shownhere employ a similar methodology to the embodiments shown in FIGS.1A-1F, however, the phase change that the build platform 100 engages inis sublimation; the transformation from a solid state directly to agaseous state. However, in contrast to the embodiments shown in FIGS.1A-1F, sublimating the build platform 100 will likely require adjustingthe pressure within the air-tight chamber 700 such that the conditionsfor the build platform 100 to sublimate can be achieved. A notableexception to this is when the build platform 100 is constructed out ofiodine, which is a solid at STP and simply requires heat to sublime.Once the build platform 100 has been sublimated the force keeping theobject 1000 stationary on the build plane 400 is removed, as shown inFIG. 2B. In some embodiments, the push mechanism 200 is also included,with the plow 201 extending into the air-tight chamber 700, as shown inFIG. 2C. This is the preferred method of ejecting a completed object1000 from the print area. Once the object 1000 has been removed thetemperature controller 500 and the pressure modulator 800 will work inconjunction to return the build platform 100 to a print-ready state. Insome embodiments, the temperature and pressure surrounding the buildplatform 100 are modulated such that the removed build platform 100reforms in a print-ready state. In other embodiments, the build platform100 is replenished in other manners.

In FIG. 2D, an alternative embodiment of the print area is shown. Here,the 3D printer deposits additional phase-changing material on top of thebuild platform 100. That is, the 3D printer prints a custom supportstructure 1200 to match the footprint of the object 1000, which can besublimated by a combination of varying the temperature and pressureinside the air-tight chamber 700. This custom support structure 1200supports the object 1000 against gravity as required and allows theobject 1000 to be easily deposited thereon. After the object 1000 hasbeen successfully printed, the support structure 1200 will change phaseand will no longer be adhered to the object 1000, allowing the object1000 to be easily removed. The support structure 1200 can be depositedby the same head that prints the object 1000, or may be deposited by aseparate print head.

When introducing elements of the present disclosure or the embodiment(s)thereof, the articles “a,” “an,” and “the” are intended to mean thatthere are one or more of the elements. Similarly, the adjective“another,” when used to introduce an element, is intended to mean one ormore elements. The terms “including” and “having” are intended to beinclusive such that there may be additional elements other than thelisted elements.

While the disclosure refers to exemplary embodiments, it will beunderstood by those skilled in the art that various changes may be made,and equivalents may be substituted for elements thereof withoutdeparting from the scope of the disclosure. In addition, manymodifications will be appreciated by those skilled in the art to adapt aparticular instrument, situation or material to the teachings of thedisclosure without departing from the spirit thereof. Therefore, it isintended that the disclosure not be limited to the particularembodiments disclosed.

It is understood that when an element is referred hereinabove as being“on” another element, it can be directly on the other element orintervening elements may be present therebetween. In contrast, when anelement is referred to as being “directly on” another element, there areno intervening elements present.

Moreover, any components or materials can be formed from a same,structurally continuous piece or separately fabricated and connected.

Advancements into the temporary adhesion properties of a variety ofmaterials have been made by Blelloch, et al. in their paper “CrystalEngineering of Molecular Solids as Temporary Adhesives”, Chem. Mater.2020, 32, 9882-9896, the contents of which are hereby incorporated byreference. Looking at some of these materials, new embodiments of thedisclosed invention are contemplated. In one embodiment, the buildplatform in accordance with the present disclosure is composed of amaterial that may be a molecular solid. In such an embodiment, themolecular solid may be configured to provide temporary bonding betweenthe build platform and the object being printed. The molecular solid maybe a polycrystalline film, a polycyclic aromatic hydrocarbon, asmall-molecule molecular solid. However, in alternate embodiments, themolecular solid may be any compound that enables effective bonding andrelease between the build platform and the object being printed. Suchbonding and release may be achieved via melt-bonding and/or sublimation.Further, as non-limiting examples, the build platform 100 may becomposed of iodine, octacyclic sulfur, hexachlorobenzene, naphthalene,(+)-camphor, dimethyl sulfone, (—)-menthol, and (S)-ibuprofen. However,other examples of material may include any compound that has a highsolid-state vapor pressure. In an alternate embodiment, the material maybe annealed.

In a further embodiment, the release of the object from the buildplatform may be enabled by an adhesive failure at the interface betweenthe build platform and the object. Such an adhesive failure may be theresult of the material having a weaker interaction with an adherend thanthe interaction within the bulk of the material. Conversely, in anembodiment, if the interactions within the bulk of the material isweaker than the interactions between the build platform and the object,there may be a cohesive failure. The material for build platform may beselected based on calculating the ratio between the adhesive failure andthe cohesive failure.

In embodiments where the material is a molecular solid or similarcompound, the object may be adhered to and released from the material bystrategically controlling the temperature and/or pressure. Althoughbonding and release may be achieved merely by adjusting the temperatureand/or pressure, in alternate embodiments, the addition of solventsand/or mechanical force may aid in release.

In an embodiment, the build platform may be a molecular solid prone tomelt-bonding. In such an embodiment, the temperature controller andpressure modulator may be utilized to change the phase of the molecularsolid. As a non-limiting example, the temperature may be raised above amolecular solid's melting point after an object has been printed,causing the molecular solid to become a liquid, releasing the buildplatform 100 from the object.

In an embodiment, the build platform may be a molecular solid capable ofsublimation at substantially 1 atm. In such an embodiment, thetemperature controller, pressure modulator, and air-tight chamber may beutilized to change the phase of the molecular solid. As a non-limitingexample, the temperature may be raised above a molecular solid'ssublimation point after an object has been printed, causing themolecular solid to become a gas, releasing the build platform from theobject. The air-tight chamber may be used to capture the molecular solidin the gaseous form.

In either the melt-bonding or sublimation embodiments, once the materialhas melted or sublimated, the temperature and/or pressure may bereverted to pre-phase change values, returning the material to a solid.The pressure may be reduced in some embodiments to increase the rate ofsublimation.

It is further understood that, although ordinal terms, such as, “first,”“second,” and “third,” are used herein to describe various elements,components, regions, layers and/or sections, these elements, components,regions, layers and/or sections should not be limited by these terms.These terms are only used to distinguish one element, component, region,layer and/or section from another element, component, region, layerand/or section. Thus, a “first element,” “component,” “region,” “layer”and/or “section” discussed below could be termed a second element,component, region, layer and/or section without departing from theteachings herein.

Features illustrated or described as part of one embodiment can be usedwith another embodiment and such variations come within the scope of theappended claims and their equivalents.

Spatially relative terms, such as “beneath,” “below,” “lower,” “above,”“upper” and the like, are used herein for ease of description todescribe one element or feature's relationship to another element(s) orfeature(s) as illustrated in the figures. It is understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if the device in thefigures is turned over, elements described as “below” or “beneath” otherelements or features would then be oriented “above” the other elementsor features. Thus, the example term “below” can encompass both anorientation of above and below. The device can be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly.

Example embodiments are described herein with reference to cross sectionillustrations that are schematic illustrations of idealized embodiments.As such, variations from the shapes of the illustrations, for example,of manufacturing techniques and/or tolerances, are to be expected. Thus,example embodiments described herein should not be construed as limitedto the particular shapes of regions as illustrated herein, but are toinclude deviations in shapes that result, for example, frommanufacturing. For example, a region illustrated or described as flatmay, typically, have rough and/or nonlinear features. Moreover, sharpangles that are illustrated may be rounded. Thus, the regionsillustrated in the figures are schematic in nature and their shapes arenot intended to illustrate the precise shape of a region and are notintended to limit the scope of the present claims.

As the invention has been described in connection with what is presentlyconsidered to be the most practical and various embodiments, it is to beunderstood that the invention is not to be limited to the disclosedembodiments, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the scope ofthe appended claims. Although specific terms are employed herein, theyare used in a generic and descriptive sense only and not for purposes oflimitation.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined in the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal language of the claims.

In conclusion, herein is presented a system and method for automatedsuccessive three-dimensional printing. The disclosure is illustrated byexample in the drawing figures, and throughout the written description.It should be understood that numerous variations are possible whileadhering to the inventive concept. Such variations are contemplated asbeing a part of the present disclosure.

1-7. (canceled)
 8. A method of ejecting a 3-dimensionally printed objectfrom a print area, comprising: accepting a 3-dimensionally printedobject formed on a build platform, the build platform formed at leastpartially from a first material having a first phase change transitionpoint different than a second phase change transition point of a secondmaterial forming the 3-dimensionally printed object; and ejecting the3-dimensionally printed object from the build platform by causing thefirst material of the build platform to undergo a phase change, whereinundergoing the phase change causes the 3-dimensionally printed object tobecome disjoined from the build platform.
 9. The method of claim 8,wherein the phase change of the first material is sublimation.
 10. Themethod of claim 9, wherein causing the first material to sublimecomprises at least one of: adjusting an ambient pressure experienced bythe first material; adjusting a temperature experienced by the firstmaterial; or adjusting the temperature and the ambient pressureexperienced by the first material.
 11. The method of claim 8, whereinthe phase change of the first material is melting.
 12. The method ofclaim 11, wherein causing the first material to melt comprises at leastone of: adjusting an ambient pressure experienced by the first material;adjusting a temperature experienced by the first material; or adjustingthe temperature and the ambient pressure experienced by the firstmaterial.
 13. The method of claim 8, further comprising: identifyingthat the 3-dimensionally printed object has been removed from the printarea; and responsive to the identifying, adjusting a temperatureexperienced by the first material to return the build platform to aprint-ready state.
 14. The method of claim 8, further comprising:identifying that the 3-dimensionally printed object has been removedfrom the print area; and responsive to the identifying, adjusting anambient pressure experienced by the first material to return the buildplatform to a print-ready state.
 15. The method of claim 8, furthercomprising: identifying that the 3-dimensionally printed object has beenremoved from the print area; and responsive to the identifying,adjusting a temperature and an ambient pressure experienced by the firstmaterial to return the build platform to a print-ready state.
 16. Asystem, comprising: a build platform configured to accept and eject a3-dimensionally printed object formed thereon, the build platformcomprising a top surface that is formed at least partially from a firstmaterial having a first phase change transition point different than asecond phase change transition point of a second material forming the3-dimensionally printed object; and a regulator in communication withthe build platform, the regulator configured to cause a phase change ofat least a portion of the build platform, wherein the phase changecauses the 3-dimensionally printed object to become disjoined from thebuild platform.
 17. The system of claim 16, wherein the phase change ofthe first material is sublimation.
 18. The system of claim 17, whereinthe regulator is configured to cause the phase change of at least theportion of the build platform by adjusting at least one of: an ambientpressure experienced by the first material; a temperature experienced bythe first material; or the temperature and the ambient pressureexperienced by the first material.
 19. The system of claim 16, whereinthe phase change of the first material is melting.
 20. The system ofclaim 19, wherein the regulator is configured to cause the phase changeof at least the portion of the build platform by adjusting at least oneof: an ambient pressure experienced by the first material; a temperatureexperienced by the first material; or the temperature and the ambientpressure experienced by the first material.
 21. The system of claim 16,further comprising: a support structure deposited on the build platformconfigured to support the 3-dimensionally printed object being formedthereon, formed from a material different than the second material. 22.The system of claim 21, wherein the material of the support structure isformed from one of the first material, the second material, or a thirdmaterial having a third phase change transition point different than thefirst phase change transition point or the second phase changetransition point.
 23. A system, comprising: an air-tight chamber; abuild platform disposed in the air-tight chamber, the build platformconfigured to accept and eject a 3-dimensionally printed object formedthereon, the build platform comprising a top surface that is formed atleast partially from a first material having a first phase changetransition point different than a second phase change transition pointof a second material forming the 3-dimensionally printed object; and aregulator in communication with the build platform, the regulatorconfigured to cause a phase change within the air-tight chamber of atleast a portion of the build platform, wherein the phase change causesthe 3-dimensionally printed object to become disjoined from the buildplatform.
 24. The system of claim 23, wherein the regulator is apressure regulator configured to adjust an ambient pressure experiencedby the first material within the air-tight chamber.
 25. The system ofclaim 23, wherein the regulator is a temperature regulator configured toadjust a temperature experienced by the first material within theair-tight chamber.
 26. The system of claim 23, wherein the regulator isconfigured to adjust a temperature and an ambient pressure experiencedby the first material within the air-tight chamber.
 27. The system ofclaim 23, further comprising: a support structure deposited on the buildplatform configured to support the 3-dimensionally printed object beingformed thereon.